US20230078662A1 - Fiber-reinforced composite material and method of manufacturing same - Google Patents

Fiber-reinforced composite material and method of manufacturing same Download PDF

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Publication number
US20230078662A1
US20230078662A1 US17/902,069 US202217902069A US2023078662A1 US 20230078662 A1 US20230078662 A1 US 20230078662A1 US 202217902069 A US202217902069 A US 202217902069A US 2023078662 A1 US2023078662 A1 US 2023078662A1
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United States
Prior art keywords
fiber
fabric
composite material
reinforced composite
resin
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US17/902,069
Inventor
Young Ho Choi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hyundai Motor Co
Kia Corp
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Hyundai Motor Co
Kia Corp
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Assigned to HYUNDAI MOTOR COMPANY, KIA CORPORATION reassignment HYUNDAI MOTOR COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHOI, YOUNG HO
Publication of US20230078662A1 publication Critical patent/US20230078662A1/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B29B15/125—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by dipping
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/008—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft characterised by weave density or surface weight
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/30—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
    • D03D15/37—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments with specific cross-section or surface shape
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/54—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads coloured
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons
    • D06M15/248—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons containing chlorine
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters
    • D06M15/513—Polycarbonates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/55—Epoxy resins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0845—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/10—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
    • D10B2321/101—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide modacrylic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/022—Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • the present disclosure relates to a fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material. More particularly, the present disclosure relates to a fiber-reinforced composite material including a fabric manufactured by weaving a weft and a warp, and a resin with which the fabric is impregnated and/or coated, wherein the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • CFRP Carbon-fiber-reinforced plastic
  • An object of the present disclosure is to provide a method of manufacturing a fiber-reinforced composite material, which is not limited with regard to weaving devices and for which the weaving speed may be increased.
  • Another object of the present disclosure is to provide a fiber-reinforced composite material having a low specific gravity, thereby being capable of lowering the weight of a molded article.
  • Still another object of the present disclosure is to provide a fiber-reinforced composite material capable of realizing various colors of fibers.
  • Yet another object of the present disclosure is to provide a fiber-reinforced composite material that is not limited with regard to the weave pattern of the fabric, regardless of the shape of parts.
  • An embodiment of the present disclosure provides a fiber-reinforced composite material including a fabric woven with a warp and a weft and a resin applied to the fabric, in which the warp may include a synthetic fiber, a carbon fiber, or a combination thereof, and the weft may include a synthetic fiber.
  • the fabric may be weaved in any one of a plain weave, a twill weave, or a satin weave.
  • the synthetic fiber of the warp and/or the weft may include polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
  • PET polyethylene terephthalate
  • PP polypropylene
  • the resin may include urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • the resin may be applied by impregnating or coating the fabric.
  • the weaving density of the fabric may be in a range of 4 to 40 count/inch.
  • the shape of the cross-section of the synthetic fiber of the warp and/or the weft includes a circular shape, an oval shape, a polygonal shape, a flat shape, a multilobal shape, or any combination thereof.
  • the aspect ratio of the synthetic fiber having a flat cross-sectional shape may be in a range of 1:1.2 to 1:5.
  • Another embodiment of the present disclosure provides a method of manufacturing a fiber-reinforced composite material.
  • the method includes manufacturing a fabric by weaving fibers, applying a resin to the fabric, and curing the resin applied to the fabric.
  • the fabric may be manufactured by weaving fibers as a warp and a weft.
  • the warp may include a synthetic fiber, a carbon fiber, or a combination thereof, and the weft may include a synthetic fiber.
  • the weaving speed may range from about 110 m/day or more.
  • the curing the resin may be performed for about 100 seconds or less.
  • the present disclosure pertains to a fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material. More particularly, the present disclosure pertains to a fiber-reinforced composite material including a fabric manufactured by weaving a weft including a synthetic fiber and a warp including a synthetic fiber, a carbon fiber, or a combination thereof, and a resin with which the fabric is impregnated and/or coated.
  • the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • the method of manufacturing the fiber-reinforced composite material includes manufacturing a fabric by weaving fibers, applying a resin to the fabric, and curing the resin applied to the fabric.
  • a fabric is manufactured by weaving fibers.
  • the fabric may be manufactured by weaving fibers in the form of a warp and a weft.
  • the weaving density of the fabric may be in a range of 4 to 40 count/inch.
  • the weaving density thereof is less than 4 count/inch, the number of yarns per unit length is low, forming a pattern with a large warp and weft width, and the pattern is larger than that of tuning parts for vehicles, which deteriorates aesthetics.
  • the weaving density thereof exceeds 40 count/inch, there are too many warp/weft yarns per unit length, making it difficult to recognize the unique pattern of the carbon fabric.
  • the weaving speed may be 100 m/day or more.
  • the fabric may be woven in any one of a plain weave, a twill weave, or a satin weave using the warp and weft.
  • the warp includes a synthetic fiber, a carbon fiber, or a combination thereof.
  • the weft includes a synthetic fiber.
  • the cross-section of the synthetic fiber of the warp and/or the weft has at least one shape selected from among a circular shape, an oval shape, a polygonal shape, a flat shape, and a multilobal shape.
  • the flat shape may refer to a rectangular shape elongated in any one direction.
  • the multilobal shape may refer to a fiber shape characterized by a large number of leaves.
  • the multilobal shape may include a trilobal shape, a pentalobal shape, an octolobal shape, or any combination thereof.
  • the aspect ratio of the synthetic fiber having a flat shape of the cross-section may be in a range of 1:1.2 to 1:5.
  • the aspect ratio thereof is less than 1:1.2, the three-dimensional (3D) patterning effect is the same as a circular shape, whereas if the aspect ratio thereof exceeds 1:5, the outer appearance may be deteriorated due to fiber kinking.
  • the synthetic fiber of the warp and/or the weft includes polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
  • a resin is applied to the fabric. More specifically, the resin is applied by impregnating and/or coating the fabric therewith.
  • the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • the resin applied to the fabric is cured.
  • the resin applied to the fabric may be processed for 100 seconds or less.
  • the fiber-reinforced composite material includes a fabric woven with a warp and a weft, and a resin applied to the fabric.
  • the warp may include a synthetic fiber, a carbon fiber, or a combination thereof.
  • the weft may include a synthetic fiber.
  • the fabric may be woven in any one of a plain weave, a twill weave, or a satin weave.
  • the synthetic fiber of the warp and/or the weft includes polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
  • the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • the resin is applied by impregnating and/or coating the fabric.
  • the cross-section of the synthetic fiber may have at least one shape selected from among a circular shape, an oval shape, a polygonal shape, a flat shape, a multilobal shape, combinations thereof, or other shapes.
  • the aspect ratio of the synthetic fiber may have a flat cross-sectional shape of 1:1.2 to 1:5.
  • Respective fiber-reinforced composite materials were manufactured using the compositions under the manufacturing conditions set forth in Table 1 below.
  • the manufacturing conditions are as follows.
  • Respective fiber-reinforced composite materials were manufactured under the manufacturing conditions set forth in Table 2 using the fabrics and resins set forth in Table 1, after which the physical properties thereof were measured. The results thereof are shown in Table 3 below.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Woven Fabrics (AREA)

Abstract

A fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material are disclosed. The fiber-reinforced composite material includes a fabric manufactured by weaving a weft including a synthetic fiber and a warp including a synthetic fiber, a carbon fiber, or a combination thereof, and a resin with which the fabric is impregnated and/or coated, wherein the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • This application claims under 35 U.S.C. § 119(a) the benefit of priority to Korean Patent Application No. 10-2021-0118132, filed on Sep. 6, 2021, the entire contents of which are incorporated herein by reference.
    • BACKGROUND (a) Technical Field
  • The present disclosure relates to a fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material. More particularly, the present disclosure relates to a fiber-reinforced composite material including a fabric manufactured by weaving a weft and a warp, and a resin with which the fabric is impregnated and/or coated, wherein the resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
    • (b) Background Art
  • Carbon-fiber-reinforced plastic (CFRP) is being applied to aerospace, sports, and high-performance automotive structural parts due to the superior mechanical properties and low specific gravity thereof compared to metals. In order to take advantage of the high-grade and high-performance consumer perception of CFRP, CFRP has started to be applied to decorative parts for luxury cars.
  • However, when a carbon fiber fabric is used for simple decorative parts, rather than structural parts, a weft is moved using a special loom equipped with a mechanical grip in the process of weaving a decorative patterned fabric due to the brittleness of carbon fiber, and thus the rate of production is decreased, and many limitations are imposed thereon. Moreover, carbon fiber is heavy because the specific gravity of the carbon fiber is 1.8, which is higher than that of various synthetic fibers. Furthermore, it is difficult to realize various colors and there are many restrictions on the weave of the fabric depending on the shape of parts.
    • SUMMARY OF THE DISCLOSURE
  • An object of the present disclosure is to provide a method of manufacturing a fiber-reinforced composite material, which is not limited with regard to weaving devices and for which the weaving speed may be increased.
  • Another object of the present disclosure is to provide a fiber-reinforced composite material having a low specific gravity, thereby being capable of lowering the weight of a molded article.
  • Still another object of the present disclosure is to provide a fiber-reinforced composite material capable of realizing various colors of fibers.
  • Yet another object of the present disclosure is to provide a fiber-reinforced composite material that is not limited with regard to the weave pattern of the fabric, regardless of the shape of parts.
  • The objects of the present disclosure are not limited to the foregoing. The objects of the present disclosure are able to be understood through the following description and to be realized by the means described in the claims and combinations thereof.
  • An embodiment of the present disclosure provides a fiber-reinforced composite material including a fabric woven with a warp and a weft and a resin applied to the fabric, in which the warp may include a synthetic fiber, a carbon fiber, or a combination thereof, and the weft may include a synthetic fiber.
  • The fabric may be weaved in any one of a plain weave, a twill weave, or a satin weave.
  • The synthetic fiber of the warp and/or the weft may include polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
  • The resin may include urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
  • The resin may be applied by impregnating or coating the fabric.
  • The weaving density of the fabric may be in a range of 4 to 40 count/inch.
  • The shape of the cross-section of the synthetic fiber of the warp and/or the weft includes a circular shape, an oval shape, a polygonal shape, a flat shape, a multilobal shape, or any combination thereof.
  • The aspect ratio of the synthetic fiber having a flat cross-sectional shape may be in a range of 1:1.2 to 1:5.
  • Another embodiment of the present disclosure provides a method of manufacturing a fiber-reinforced composite material. The method includes manufacturing a fabric by weaving fibers, applying a resin to the fabric, and curing the resin applied to the fabric. The fabric may be manufactured by weaving fibers as a warp and a weft. The warp may include a synthetic fiber, a carbon fiber, or a combination thereof, and the weft may include a synthetic fiber.
  • The weaving speed may range from about 110 m/day or more.
  • The curing the resin may be performed for about 100 seconds or less.
    • DETAILED DESCRIPTION
  • The above and other objects, features, and advantages of the present disclosure are further understood from the following embodiments taken in conjunction with the accompanying drawings. The present disclosure is not limited to the embodiments disclosed herein and may be modified into different forms. These embodiments are provided to thoroughly explain the disclosure and to sufficiently transfer the spirit of the present disclosure to those of ordinary skill in the art.
  • The terms “comprise,” “include,” “have,” etc., when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof. Also, when an element such as a layer, film, area, or sheet is referred to as being “on” another element, it may be directly on the other element, or intervening elements may be present therebetween. Similarly, when an element such as a layer, film, area, or sheet is referred to as being “under” another element, it may be directly under the other element, or intervening elements may be present therebetween.
  • Unless otherwise specified, all numbers, values, and/or representations that express the amounts of components, reaction conditions, polymer compositions, and mixtures used herein are to be taken as approximations including various uncertainties affecting measurement that inherently occur in obtaining these values, among others, and thus should be understood to be modified by the term “about” in all cases. Furthermore, when a numerical range is disclosed in this specification, the range is continuous, and includes all values from the minimum value of said range to the maximum value thereof, unless otherwise indicated. Moreover, when such a range pertains to integer values, all integers including the minimum value to the maximum value are included, unless otherwise indicated.
  • The present disclosure pertains to a fiber-reinforced composite material and a method of manufacturing the fiber-reinforced composite material. More particularly, the present disclosure pertains to a fiber-reinforced composite material including a fabric manufactured by weaving a weft including a synthetic fiber and a warp including a synthetic fiber, a carbon fiber, or a combination thereof, and a resin with which the fabric is impregnated and/or coated. The resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
    • Method of Manufacturing Fiber-Reinforced Composite Material
  • The method of manufacturing the fiber-reinforced composite material includes manufacturing a fabric by weaving fibers, applying a resin to the fabric, and curing the resin applied to the fabric.
    • Manufacturing Fabric
  • A fabric is manufactured by weaving fibers.
  • The fabric may be manufactured by weaving fibers in the form of a warp and a weft.
  • The weaving density of the fabric may be in a range of 4 to 40 count/inch. Here, if the weaving density thereof is less than 4 count/inch, the number of yarns per unit length is low, forming a pattern with a large warp and weft width, and the pattern is larger than that of tuning parts for vehicles, which deteriorates aesthetics. On the other hand, if the weaving density thereof exceeds 40 count/inch, there are too many warp/weft yarns per unit length, making it difficult to recognize the unique pattern of the carbon fabric.
  • The weaving speed may be 100 m/day or more.
  • The fabric may be woven in any one of a plain weave, a twill weave, or a satin weave using the warp and weft.
  • The warp includes a synthetic fiber, a carbon fiber, or a combination thereof.
  • The weft includes a synthetic fiber.
  • The cross-section of the synthetic fiber of the warp and/or the weft has at least one shape selected from among a circular shape, an oval shape, a polygonal shape, a flat shape, and a multilobal shape. The flat shape may refer to a rectangular shape elongated in any one direction. The multilobal shape may refer to a fiber shape characterized by a large number of leaves. The multilobal shape may include a trilobal shape, a pentalobal shape, an octolobal shape, or any combination thereof.
  • The aspect ratio of the synthetic fiber having a flat shape of the cross-section may be in a range of 1:1.2 to 1:5. Here, if the aspect ratio thereof is less than 1:1.2, the three-dimensional (3D) patterning effect is the same as a circular shape, whereas if the aspect ratio thereof exceeds 1:5, the outer appearance may be deteriorated due to fiber kinking.
  • The synthetic fiber of the warp and/or the weft includes polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
    • Applying Resin
  • A resin is applied to the fabric. More specifically, the resin is applied by impregnating and/or coating the fabric therewith.
  • The resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
    • Curing Resin
  • The resin applied to the fabric is cured.
  • The resin applied to the fabric may be processed for 100 seconds or less.
    • Fiber-Reinforced Composite Material
  • The fiber-reinforced composite material includes a fabric woven with a warp and a weft, and a resin applied to the fabric.
  • The warp may include a synthetic fiber, a carbon fiber, or a combination thereof.
  • The weft may include a synthetic fiber.
  • The fabric may be woven in any one of a plain weave, a twill weave, or a satin weave.
  • The synthetic fiber of the warp and/or the weft includes polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
  • The resin includes urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof. The resin is applied by impregnating and/or coating the fabric. The cross-section of the synthetic fiber may have at least one shape selected from among a circular shape, an oval shape, a polygonal shape, a flat shape, a multilobal shape, combinations thereof, or other shapes. Here, the aspect ratio of the synthetic fiber may have a flat cross-sectional shape of 1:1.2 to 1:5.
  • A better understanding may be obtained through the following examples. These examples are merely set forth to illustrate the present disclosure and are not to be construed as limiting the scope of the present disclosure.
    • Examples and Comparative Examples
  • Respective fiber-reinforced composite materials were manufactured using the compositions under the manufacturing conditions set forth in Table 1 below. Here, the manufacturing conditions are as follows.
  • TABLE 1
    Composition for fiber-reinforced composite material
    Fabric
    Warp Weft
    (material/ (material/
    Category fineness) fineness) Weave Resin
    Example 1 PET/1,500 PET/1,500 Twill Urethane
    acrylate
    Example 2 PET/1,800 PET/1,800 Twill Urea
    Example 3 PET/1,500 CF/1,800 Twill Urethane
    acrylate
    Example 4 PET/1,800 PET/1,800 Plain Urethane
    acrylate
    Example 5 CF/1,800 PET/1,500 Twill Urethane
    acrylate
    Example 6 PET/1,500 PET/1,500 Twill Epoxy
    Comparative CF/1,870 CF/1,870 Twill Epoxy
    Example 1
    Comparative CF/1,870 CF/1,870 Plain Epoxy
    Example 2
    Comparative CF/1,870 KF/1,600 Twill Epoxy
    Example 3
    Comparative CF/1,870 CF(coating)/ Twill Epoxy
    Example 4 1,870
    PET = Polyethylene terephthalate
    CF = Carbon fiber
    KF = Kevlar Fiber
    CF(coating) = Various colors are realized using pigments on surface irregularities in the anodizing process after depositing Al (aluminum) to a thickness of 20 nm to 500 nm on the surface of carbon fiber.
    • Test Example 1
  • The speed at which each of the fabrics in Table 1 was capable of being woven and the speed at which the fabric impregnated with the resin was capable of being cured were measured, and the results thereof are shown in Table 2 below.
  • TABLE 2
    Weaving speed Curing time
    Category (m/day) (sec)
    Example 1 600 45
    Example 2 1,000 60
    Example 3 110 45
    Example 4 1,000 45
    Example 5 150 45
    Example 6 600 7,200
    Comparative Example 1 100 7,200
    Comparative Example 2 100 7,200
    Comparative Example 3 100 7,200
    Comparative Example 4 100 7,200
    • Test Example 2
  • Respective fiber-reinforced composite materials were manufactured under the manufacturing conditions set forth in Table 2 using the fabrics and resins set forth in Table 1, after which the physical properties thereof were measured. The results thereof are shown in Table 3 below.
  • TABLE 3
    3D
    Permeability Maximum patterning
    Specific coefficient shear load effect
    Category gravity (×10−10 m2) (N) (1-5)
    Example 1 1.45 K1 2.90 K2 2.74 11 4
    Example 2 1.5 K1 3.02 K2 2.30 21 4
    Example 3 1.45 K1 1.34 K2 2.09 16 5
    Example 4 1.45 K1 2.87 K2 2.22 22 5
    Example 5 1.45 K1 2.69 K2 0.83 19 5
    Example 6 1.45 K1 2.90 K2 2.74 11 4
    Comparative 1.6 K1 1.24 K2 0.75 38 5
    Example 1
    Comparative 1.6 Ki 1.12 K2 0.74 50 5
    Example 2
    Comparative 1.56 K1 1.09 K2 0.76 45 5
    Example 3
    Comparative 1.6 K1 0.98 K2 1.26 50 4
    Example 4
    K1: Resin impregnation coefficient in weft direction
    K2: Resin impregnation coefficient in warp direction
    Measurement method
    Weaving speed: loom RPM × weaving density (count/inch) × unit time
    Curing time: Measurement of the minimum time taken to completely impregnate the fabric with the resin, meaning that there is no unformed portion and there is no deformation during demolding
    Permeability coefficient: Measurement according to the method described in Transport in Porous Media 47: 363-380, 2002
    Maximum shear load (N): Measurement according to the method described in ASTM D8067 “Standard Test Method for In-Plane Shear Properties of Sandwich Panels Using a Picture Frame Fixture”
    3D patterning effect: Visual evaluation by 3 design experts (5: very good, 4: good, 3: fair, 2: poor, 1: none)
  • As is apparent from the above description, it is possible to provide a method of manufacturing a fiber-reinforced composite material, which is not limited with regard to weaving devices and for which the weaving speed can be increased.
  • According to the present disclosure, it is possible to provide a fiber-reinforced composite material having a low specific gravity, thereby being capable of lowering the weight of a molded article.
  • According to the present disclosure, it is possible to provide a fiber-reinforced composite material capable of realizing various colors of fibers.
  • According to the present disclosure, it is possible to provide a fiber-reinforced composite material that is not limited with regard to the weave pattern of the fabric, regardless of the shape of parts.
  • The effects of the present disclosure are not limited to the above-mentioned effects. It should be understood that the effects of the present disclosure include all effects that can be inferred from the description of the present disclosure.

Claims (18)

What is claimed is:
1. A fiber-reinforced composite material comprising:
a fabric woven having a warp and a weft; and
a resin applied to the fabric,
wherein the warp comprises a synthetic fiber, a carbon fiber, or a combination thereof, and
wherein the weft comprises a synthetic fiber.
2. The fiber-reinforced composite material of claim 1, wherein the fabric comprises a plain fabric, a twill fabric, a satin fabric, or any combination thereof.
3. The fiber-reinforced composite material of claim 1, wherein the synthetic fiber of the warp comprises polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
4. The fiber-reinforced composite material of claim 1, wherein the synthetic fiber of the weft comprises polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
5. The fiber-reinforced composite material of claim 1, wherein the resin comprises urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
6. The fiber-reinforced composite material of claim 1, wherein the resin has been applied to the fabric by impregnating or coating the fabric.
7. The fiber-reinforced composite material of claim 1, wherein the fabric has a weaving density in a range of 4 to 40 count/inch.
8. The fiber-reinforced composite material of claim 1, wherein a shape of a cross-section of the synthetic fiber of the warp and/or the weft comprises a circular shape, an oval shape, a polygonal shape, a flat shape, a multilobal shape, or any combination thereof.
9. The fiber-reinforced composite material of claim 7, wherein an aspect ratio of the synthetic fiber of the warp and/or the weft having a flat shape of a cross-section is in a range of 1:1.2 to 1:5.
10. A method of manufacturing a fiber-reinforced composite material, the method comprising:
manufacturing a fabric by weaving fibers as a warp and a weft;
applying a resin to the fabric; and
curing the resin applied to the fabric,
wherein the warp comprises a synthetic fiber, a carbon fiber, or a combination thereof, and
wherein the weft comprises a synthetic fiber.
11. The method of claim 10, wherein a weaving speed of the weaving of the fibers is 110 m/day or more.
12. The method of claim 11, wherein the curing of the resin is performed for 100 seconds or less.
13. The method of claim 10, wherein the curing of the resin is performed for 100 seconds or less.
14. The method of claim 10, wherein the synthetic fiber of the warp comprises polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
15. The method of claim 10, wherein the synthetic fiber of the weft comprises polyethylene terephthalate (PET), nylon, polypropylene (PP), acryl, or any combination thereof.
16. The method of claim 10, wherein the resin comprises urethane, urethane acrylate, urea, epoxy, acryl, polycarbonate, polymethyl methacrylate, polypropylene, polyvinyl chloride, polyvinyl butyral, or any combination thereof.
17. The method of claim 10, wherein the resin is applied to the fabric by impregnating or coating the fabric.
18. The method of claim 10, wherein the fabric has a weaving density in a range of 4 to 40 count/inch.
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